Vulcanizable compositions comprising a major portion of epr or epdm and a minor portion of amorphous polypropylene

ABSTRACT

VULCANIZABLE HIGH MOLECULAR WEIGHT ELASTOMER COMPOSITIONS COMPRISING (1) A HIGH MOLECULAR WEIGHT VULCANIZABLE ELASTOMER SELECTED FROM (A) SATURATED COPOLYMERS OF ETHYLENE AND PROPYLENE OR BUTENE-1, AND (B) LOW-UNSATURATION TERPOLYMERS OF ETHYLENE, PROPYLENE AND A NON-CONJUGATED POLYENE, (2) AN EXTENDER COMPRISING FROM ABOUT 1 TO 90 PARTS OF SUBSTANTIALLY AMORPHOUS POLYPROPYLENE PER 100 PARTS OF SAID VULCANIZABLE ELASTOMER; AND (3) A CURING AGENT.

United States Patent 3,564,080 VULCANIZABLE COMPOSITIONS COMPRIS- ING A MAJOR PORTION OF EPR OR EPDM AND A MINOR PORTION OF AMORPHOUS POLYPROPYLENE Giovanni Pedretti, Ferrara, Gino Panciroli, Bologna, and

Augusto Portolani, Milan, Italy, assignors to Montecatini Edison S.p.A., Milan, Italy, a corporation of Italy No Drawing. Continuation-impart of application Ser. No. 438,373, Mar. 9, 1965. This application July 9, 1968, Ser. No. 743,329

Claims priority, application Italy, Mar. 10, 1964, 5,262/ 64; June 25, 1964, 13,972/ 64 Int. Cl. C08f 37/18 US. Cl. 260-897 11 Claims ABSTRACT OF THE DISCLOSURE vulcanizable high molecular weight elastomer compositions comprising (1) a high molecular weight vulcanizable elastomer selected from (a) saturated copolymers of ethylene and propylene or butene-l, and (b) low-unsaturation terpolymers of ethylene, propylene and a non-conjugated polyene, (2) an extender comprising from about 1 to 90 parts of substantially amorphous polypropylene per 100 parts of said vulcanizable elastomer; and (3) a curing agent.

CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation-in-part of copending application Ser. No. 438,373, filed Mar. 9, 1965.

BACKGROUND OF THE INVENTION (1) Field of the invention This invention relates to new, vulcanizable compositions and, more particularly, to such compositions comprising mixtures of high molecular weight, saturated, linear, amorphous and vulcanizable copolymers of ethylene with higher alpha-olefins, or of high molecular Weight, low-unsaturation, amorphous vulcanizable terpolymers of ethylene, a higher alpha-olefin and cyclic or acyclic polyene, with substantially amorphous polypropylene as defined hereinafter as an extender or diluent for the copolymer or terpolymer.

(2) Description of the prior art Synthetic elastomeric copolymerizates of ethylene and a higher alpha-olefin, 'CH =CHR in which R is a hydrocarbon radical, more particularly a lower alkyl radical, preferably propylene and/or butene-l, which are vulcanizable to valuable synthetic rubbers or elastomers were first disclosed by Natta et al., who obtained them by copolymerizing ethylene and the higher alphaolefin under special conditions and by means of halogen-containing catalyst systems prepared by mixing hydrocarbon-soluble vanadium compounds with organometallic compounds, more particularly alkyl aluminum compounds. These copolymers are characterized by being amorphous, free of unsaturation and substituent groups, and, as normally obtained, in the absence of molecular weight regulating agents, by having a high molecular weight indicated by, or reflected in, a high Mooney viscosity.

While these copolymers yield vulcanizates having excellent mechanical characteristics, some difficulty may be encountered in the processing thereof, for instance in extrusion and spinning operations, due to their high viscosity which results from the high molecular weight, which is typically above 20,000, usually above 50,000, and may be 500,000 or higher.

Those problems can be eliminated or minimized by reducing the viscosity of the amorphous copolymers, either by including suitable molecular weight regulating agents, such as hydrogen or diethyl zinc, in the copolymerization Zone, or by after-treatments performed on the copolymers and involving the use of extenders or diluents which improve the workability of the copolymers without impairing the mechanical properties of the vulcanizates obtained therefrom. The inclusion of molecular weight regulating agents in the copolymerization zone, for controlling (reducing) the molecular weight of the amorphous copolymerizate as it is formed, has the disadvantage that the molecular weight of the final copolymerizate varies over a wide range, and hence the uniformity of the product is impaired.

After-treatments involving the use of extenders which act as diluents for the copolymers or the terpolymers offer the most desirable means of solving the problem, provided the extender is of relatively low cost and thus economically practicable, and provided, also, that the extender does not interfere with the curing agents or curing operation,

and does not adversely affect the mechanical properties of the vulcanizates.

Dilnents of the type conventionally used with plastic materials such as polyvinylchloride, for example, and which include such polar compounds as pohsphoric acid esters, phthalic acid esters, and benzoic acid esters, have not proved suitable for use as diluents or extenders for the amorphous, vulcanizable copolymers or terpolymers. The latter are non-polar in character and are not compatible with polar compounds.

Mineral oils, particularly highly refined paraffin oils, are good extenders for increasing the workability of the copolymers or terpolymers, but, due to the nature of such oils and the handling involved in the preparation thereof, those oils are relatively expensive and can increase the cost of the final vulcanizates to the point where the latter are not commercially competitive with other, less costly, synthetic rubbers. On the other hand, aromatic oils, which are less expensive because they are by-products of the petrochemical industry, are generally preferred for the H terpolymers of ethylene with propylene and nonconjugated The present invention provides new vulcanizable compositions comprising the high molecular weight amorphous linear copolymers or terpolymers of the above type, and an extender or diluent for the copolymers or terpolymers which has marked practical advantages over the extenders heretofore used or proposed for use.

More particularly, the invention provides new vulcanizable compositions comprising high molecular weight, amorphous, linear vulcanizable copolymers of ethylene and propylene or butene-l, or amorphous, linear, lowunsaturation vulcanizable terpolymers of ethylene, propylene or butene-l, and a cyclic or acyclic polyene, extended with a minor amount (about 190 parts per parts of the copolymer or terpolymer) of a substantially amorphous polypropylene as defined herein, which compositions are characterized by easy workability and are convertible, by vulcanization, to synthetic rubbers or elastomers having excellent mechanical properties.

DESCRIPTION OF THE PREFERRED EMBODIMENTS By the term substantially amorphous polypropylene as used herein, we mean to include polypropylene consisting essentially of atactic, linear macromolecules. This polymer is completely or substantially soluble in boiling n-heptane. This definition includes the by-product of the commercial production of isotactic polypropylene by polymerizing propylene in an inert liquid polymerization diluent or medium and in contact with a catalyst capable of orienting the polymerization of propylene preferentially to the production of isotactic macromolecules. Such polypropylne remaining in solution in the inert polymerization diluent may comprise a small amount of isotactic polypropylene insoluble in boiling n-heptane and have an isotacticity index range of from 2% to The term substantially amorphous polypropylene" as used herein also is meant to include polypropylene substantially made up of atactic, linear, regularly head-totail macromolecules which can be separated from a crude, total polypropylene consisting of sterically differentiated macromolecules including isotactic macromolecules, by extracting the crude total polypropylene with a suitable solvent, for example, ethyl ether at its boiling point.

In general, the substantially amorphous polypropylene used in the practice of this invention has the following characteristics:

Intrinsic viscosity (in Tetralin at 135 C.) 0.2-0.5 Molecular weight 14,00048,000

X-ray crystallinity (percent) 10-17 Specific gravity (kg/l.) 0.870 Ash content 0.2-0.46

Softening point C.) l54162 isotacticity index (percent) 2-10 Volatile matter (percent) 27 The advantages of using the substantially amorphous polypropylene as the extender or diluent for the high molecular weight, vulcanizable copolymers or terpolymers include the fact that, due to its structure, the polypropylene is more compatible with the copolymers or terpolymers than the extenders or diluents used heretofore, including paraffin oils; the fact that the copolymers or terpolymers can be extended with larger amounts of the polypropylene than of the previously used extenders, for instance, a paraffinic oil or a mixture of such oils; the fact that the polypropylene can be a waste or by-product as mentioned hereinabove and thus a very economical extender or diluent for the compolymers or terpolymers even when used in relatively large amounts; and the surprising and unexpected fact that the values for the various physical parameters of the vulcanizates obtained from the polypropylene-extended copolymers and terpolymers are higher than the values for the same parameters of the vulcanizates obtained from the copolymers and terpolymers extended with other diluents including corresponding amounts of parafiin oils, indicating that the use of the polypropylene as extender or diluent has a favorable influence or various mechanical characteristics of the vulcanizates.

The polypropylene-extended vulcanizable copolymers of ethylene and the higher alpha-olefin, preferably propylene or butene-l, can be vulcanized with peroxide agents and free radical acceptors. The prolypropyleneextended vulcanizable low-unsaturation terpolymers of ethylene, a higher alpha-olefin (preferably propylene or butene-l) and a cyclic or acyclic polyene can be vulcanized with the usual sulfur formulations or with per- Oxide agents and free radical acceptors in the same manner as the copolymers.

The vulcanizates obtained from the polypropyleneextended high molecular weight copolymers and terpolymers have excellent resistance to heat, oxidation and ageing. These characteristics are only slightly poorer than those possessed by the vulcanizates obtained from the high molecular weight copolymers and terpolymers per se, in the absense of an extender or diluent.

The new vulcanizable compositions of the invention comprise the high molecular weight copolymers and terpolymers, the substantially amorphous polypropylene, curing agents, and, usually, a reinforcing filler. Antioxidants may also be included in the compositions which can be readily processed, for example extruded or spun, as a result of the use of the polypropylene as extender.

The amount of substantially amorphous polypropylene present in the composition as extender or diluent is from about 1 to 90 parts by weight, preferably from about 10 to 70 parts by weight, per 100 parts of the copolymer or terpolymer, when peroxide agents are used for the vulcanization, and preferably from 10 to parts by weight per 100 parts of the terpolymer when the terpolymerizate is vulcanized using sulfur-l-accelerator formulations.

The foregoing different preferred ranges which depend upon the curing system used in the formulations are due to the fact that the substantially amorphous polypropylene undergoes some crosslinking with peroxides, thus taking part in the crosslinked structure formation, whereas it is completely inert toward the sulfur+accelerators system, and in the presence of this vulcanizing system is merely an inert extender.

When the composition is based on a high molecular weight, vulcanizable copolymer of ethylene and, e.g., propylene or butene-l, the organic peroxide is used in an amount between 0.1 and 10 parts by weight, per 100 parts of the copolymer, and the free radical acceptor is used in an amount which is less than half the amount of the peroxide. Suitable free radical acceptors include sulfur, quinone compounds, and furfural and its derivatives. The use of peroxy compounds and free radical acceptors in the vulcanization of the linear, saturated, high molecular weight, amorphous copolymers of ethylene and a higher alpha-olefin such as propylene and butene-l is known in the art.

The ethylene/propylene or ethylene/butene-l copolymers used in practicing this invention are amorphous, contain from about 20% to 80%, preferably from about 30% to by mols of ethylene, and have a Mooney viscosity ML (1+4)- at 100 C. in the range of from about 30 to 130, preferably from about 60 to 90. Such copolymers can be obtained by copolymerizing the monomers in an inert liquid diluent in contact with halogencontaining catalyst systems prepared from hydrocarbonsoluble vanadium compounds and organo-metallic compounds, While maintaining, in the gas phase, an ethylene/ propylene molar ratio of at least 1:1 or an ethylene/ butene-l molar ratio of at least 1:4. Suitable catalytic systems can be prepared from VCl VOC1 or VAc (Ac=acetylacetonate) and aluminum trialkyls or aluminum alkyl halides. Copolymerization temperatures between l00 C. and +100 C. can be used.

When the composition is based on the amorphous, high molecular weight, linear, low-unsaturation terpolymers of ethylene, a higher alpha-olefin, CH =CHR, in which R is a lower alkyl radical (preferably propylene) and a polyene, the terpolymer used contains from about 20 to by mols of ethylene and from 0.1 to 18% by mols of a non-conjugated polyene which may be, for example, cyclooctadiene-l,5; dicyclopentadiene; cyclododecatriene- 1,5,9; cyclododecadiene-l,7; cycloheptadiene-1,4; cyclohexadiene-1,4; norbornadiene; methylen-norbornene; dimethyl-tetrahydroindene; 6-methyl-heptadiene-1,5, hexadiene-1,4, 6-methyl-4,7,8,9-tetrahydroindene, ethylidenenorbornene, etc., the balance (to being units from the higher alpha-olefin.

Said terpolymers also have a high molecular weight above about 20,000, generally in the range of about 60,000 to 500,000, and can be obtained by the same methods used to produce the ethylene/propylene or ethylene/butene-l copolymers.

The terpolymers are sulfur-vulcanizable and can be vulcanized with formulations comprising sulfur in an amount from about 0.75 to 2.5 parts, preferably about 2 parts, by weight per 100 parts of the terpolymers. Accelerators included in the formulations are used in lower amounts, preferably from 0.5 to 2.5 parts per 100 parts of terpolymer. Examples of such accelerators include tetramethylthiuramdisulfide, zinc diethyl dithiocarbamate, dipentamethylthiuramdisulfide, 2-mercaptobenzothi-azole, dibenzothiazole disulfied and diphenylguanidine.

The compositions of the invention can be vulcanized at temperatures ranging from 110 C. to 220 C., preferably from 140 C. to 180 C.

The following examples are presented to illustrate the invention and are not intended to limit the scope thereof.

6 fined herein and successively adding black fillers, antioxidants and curing agents.

The compositions of the resulting mix were the following:

Parts by weight Sulfur 0.45

Alpha alpha bis(t.butyl-peroxy)diisopropylben- Zene Vulcanization in a press, minutes at 165 C.

Total for both polymers, apportioned as set forth in Table 2.

Table 2 gives the mechanical characteristics of the vulcanizates obtained from mixes containing ethylene-propylene copolymer and polypropylene, at various ratios.

TABLE 2 E thylenepropylene co iloymerlpolypropylene 1'2. 10

. (0 Mechanical characteristics Units 100/0 90/10 70/30 /50 30/70 10/90 Tenslle strength KgJcm. 160 160 150 135 90 50 Elongation at break. Percent- 220 250 275 325 370 420 Elastic modulus at 100%.. Kg./cm. 38 36 40 40 33 Tear strength Kgjemfl 39 44 52 55 52 42 Shore A Hardness 76 76 76 76 76 78 Residual set at 100% Percent 2 3 4 5 9 2 Extrudabllrty index at 100 C.

(Garvey Dle) 12 14 15 16 16 16 EXAMPLE 1 Mixes suitable for making molded articles were prepared by diluting an amorphous, linear, vulcanizable ethylene-propylene copolymer as described herein on a conventional roll mixer with diflerent amounts of polypropylene having the above mentioned characteristics and by successively adding black fillers, antioxidants and cur- Alpha alpha bis(t.butyl peroxy)diisopropyl benzene Total for both polymers, apportioned as set forth in Table 1.

Polypropylene characteristics: X-ray crystallinity, 10%;

density, 0.985; viscosity, 0.4; ash content, 0.37% Isotactic ity, 9.7% vulcanization in a press, 40 minutes at 165 C.

Table 1 gives the mechanical characteristics of the vulcanizates obtained with mixes containing the ethylenepropylene copolymer and polypropylene, depending on the ratio between the components:

Under the same conditions, vulcanization runs were carried out with mixes based on 100% of the polypropylene as defined herein, for comparison purposes. The products obtained were insufficiently vulcanized and not homogeneous and showed blisters to such an extent that they were unsuitable even for tests for evaluating the mechanical characteristics.

EXAMPLE 3 Mixes suitable for making extruded articles and containing 50 parts of polypropylene as defined herein and 50 parts of ethylene-propylene copolymer with difierent Mooney viscosity were prepared on normal roll mixers, after the addition to the copolymer blend of black fillers, antioxidants and curing agents.

The compositions of the resulting mixes were the following:

Parts by weight Ethylene-propylene copolymer (55% by mols of ethylene), ML 1+4) 100 (3.: [variedsee Table 3] 50 Polypropylene 50 FEF carbon black Polymerized 2,2,4-trimethyl-1,2-dihydroquinoline 0.5 Zinc oxide 5 Sulfur 0.45 Alpha alpha bis(t.butylperoxy)diisopropylbenzene Vulcanization in stream autoclave, 40 minutes under 6.5 atmosphere pressure.

TABLE 1 Ethylene-propylene copolymer/ polypropylene ratio.

(a) Mechanical characteristics Units 100/0 /10 70/30 50/50 30/70 Tensile strength Kg./cm. 175 173 153 124 Elongation at break. Percent. 270 4 0 400 400 400 Elastic modulus at 300% Kg-lom- 96 90 88 83 Elastic modulus at 100% Kg./cm. 32 18 18 1s 13 Tearing strength KgJcm. 29 41 42 45 54 Shore A Hardness 69 64 64 68 73 Residual set at 200% Percent 3.5 5. 5 8 13 24 Residual set at 100%.. 1. 5 5 5 12. 5 12 EXAMPLE 2 Mixes suitable for making extruded articles were prepared by diluting an ethylene-propylene copolymer on a roll mixer with various amounts of'polypropylene as de- The influence of the Mooney viscosity of the ethylenepropylene copolymer on the mechanical characteristics of the vulcanizates containing 50 parts of copolymer and 50 5 parts of the polypropylene is shown in Table 3. This example is presented only to illustrate the effect of the Mooney viscosity and is not illustrative of the present invention in that the ratio of polypropylene to copolymer is outside the scope thereof.

Two types of mixes comprising ethylene-propylene copolymers diluted with varying amounts of polypropylene as defined herein and with paraifin oil, respectively, were prepared on conventional roll mixers.

The compositions of the mixes were as follows:

Parts by weight Ethylene-propylene copolymer (55% by mols of ethylene), ML (1+4) 100 C.=80 100 Polypropylene HAF carbon black 50 Polymerized 2,2,4 trimethyl 1,2 dihydroquinoline 0.5 Zinc oxide Sulfur 0.45 Alpha-alpha bis(t.butylperoxy)diisopropylbenzene 2.5

vulcanization in a press, 40 minutes at 165 C.

1 Total for both polymers, apportioned as set forth in Table 4, part I.

Parts by weight Ethylene-propylene copolymer (55% by mols of ethylene), ML (1+4) 100 C.=8O 100 Paraflin oil FL 2 HAF carbon black 50 Sulfur 0.45 Dicumylperoxide 4 vulcanization in a press, 40 minutes at 165 C.

Total for both polymers, apportioned as set forth in Table 4. part II.

-FL 65 oil characteristics: d, 0.86; viscosity at 980 (1., 4 centistokes V.G.C. (viscosity gravity constant), 0.80.

The influence of varying the amounts of the paraffin oils and of the polypropylene on the mechanical characteristics of the vulcanizates obtained from mixes based on an ethylene-propylene copolymer having a high Mooney viscosity and of the above mentioned ingredients used as diluents is shown in Table 4.

8 EXAMPLE 5 Mixes for making molded articles were prepared by diluting an ethylene/propylene/ethylidene-norbornene terpolymer, on a conventional roll mixer, with varying 5 amounts of polypropylene as defined herein and then adding black fillers, antioxidants and curing agents.

The compositions of the mixes were the following:

Parts by weight 1O Ethylene/ (32.5% by mols) propylene/ (3.5% by mols) ethylidene-norbornene terpolymer, ML (1+4) 100 C.=73 70 Polypropylene 30 HAF carbon black 50 15 Zinc oxide 5 Dicumylperoxide 4 Vulcanization in a press, 30 minutes at 160 C.

In Table 5, the mechanical characteristics of the vulcanizates of mixes containing the terpolymer and polypropylene in a 70:30 ratio are reported.

TABLE 5 Ratio ter- 20 polymer:

p yp py Mechanical characteristics Units ene l Tensile strength Kg./crn. 150 Elongation at break... Percent.-- 455 Elastic modulus at 3007 Kg./ern. 102 Elastic modulus at 2007 Kg./crn. 72 Elastic modulus at 100%.. Kg./cm Residual set at 200% Percent.. 17 Tear strength Kg./cm. ISO hardness 70 Heat build up measured by Goodrich fleximeter, 20 lbs/30 C 35 Loss due to abrasion, Akron method. 0.270 ML (1+4) 100 C 54 1 70/30 parts by weight, 2 Break of the specimen. In 1,000 revolutionsXlO".

EXAMPLE 6 Mixes comprising ethylene-propylene copolymers diluted with varying amounts of polypropylene were prer pared onconventional roll mixers. The compositions of the mixes were the following:

Parts by weight Ethylene-propylene copolymer by mols of ethylene), ML (1+4) 100 C.=80 100 Polypropylene HAF carbon black 50 Polymerized 2,2,4-trimethyl-l,2 dihydroquinoline 0.5 Zinc oxide 5 Sulfur 0.45

53 Alpha,alpha'-bis(t.butylperoxy) diisopropylbenzene (40% in CaCO 6.25

vulcanization, 40 minutes at 165 C.

1 Total for both polymers, apportioned as set forth in Table 6.

Table 6 shows the various characteristics of the vulcanizates obtained from the above mentioned mixes, de-

TABLE 4 I Ethylene-propylene copolymer/parafiin II Ethylene-propylene copolymcr/ oil ratio polypropylene ratio (a) (b) (d) (o (0 (a (h) (0 Mechanical characteristcs Units 75/25 70/30 /35 60/40 55/45 90/10 30/70 50/50 30/70 Tensile strength Kg./ 2 150 140 120 110 90 174 154 124 101 Elongation at break Percent- 500 560 630 675 740 445 435 440 405 Elastic modulus at 300% Kg./ 2 60 45 36 25 95 90 88 Residual set at 200% Percent. 6 7. 5 0 ll 13. 5 6 8 13 21 9 pending on the ratio between the amounts of ethylenediluting an ethylene/propylene/cyclooctadiene-1,5 terpropylene copolymer and the polypropylene. polymer on a roll mixer, with various amounts of poly- TABLE 6 Ethylene-propylene copolymer/ polypropylene ratio Characteristics Units 100/0 90/10 70/30 50/50 30/70 Loss due to abrasion, Akron Method. Ce. t l 0. 227 0. 209 0. 229 0. 156 0.113 Heat build up measured at the Goodrich C 39 41 48 53 48 deflectometer 20 pound 30 C. Bonding to steel, with adhesives based Kg./ 30 47 47 32 0 on polyisocyanates. cm.

1 In 1,000 revolutionsxlo EXAMPLE 7 propylene as defined herein, and then adding black fillers, Mixes for making molded articles were prepared by fg qp z diluting an ethylene/propylene/cyclooctadiene-1,5 terf 11 cfmpwmns o t e resu tmg were the polymer, on a conventional roll mixer, with varying 0 Owmg' Parts y ht amounts of polypropylene as defined herein, and then welg adding black fillers, antioxidants and curing agents. EthylTne/ bydmols) propylellle/ (3% by The compositions of the resulting mixes were the mo S) We s lene terpo ymer ML 1 100 following. )1

' Po ypropy ene Parts by welght Ethylene/ (59% by mols) propylene/ (3% by lg black mols) cyclooctadiene-1,5 terpolymer, ML 1 mo 0X1 6 (1+4) 0 0:84 100 Phenylbetanaphthylamrne 1 Polypropylene Tetramethylthiuramdisulfide 1 HAF carbon gi m 50 Mercaptobenzothiazole 0.5 n Sulfur 2 Zmc oxide a phenylbetanaphthylamine 1 Vulcamzauon 111 a press, 60-m1nutes at 150 C. Tetramethylthiuramdisulfide 1 Total for both polymers apportioned as set forth in Mercaptobenzothiazole 0.5 Table 8. Sulfur 2 Vulcanization in a press, 60 minutes at 150 C.

1 Total for both p01 mers apportioned as Set forth in The mechanical characteristics of the vulcanizates Tame y obtained from these mixes are reported in Table 8.

TAB LE 8 Ratio ethylene-propylene cyclooetadiene- 1,5 terpolymer/polypropylene (a) (c d e 1 Mechanical characteristics Units 160/0 90/10 70/32) 5035?) 30;7( 10/ 9( Tensile strength- KgJcmJ. 198 172 147 96 51 29A Elongation at break Percent 250 230 240 230 100 Elastic modulus at 200 o KgJcmfl. 171 155 128 90 Elastic modulus at 100% Kg./cm. 71 65 53 50 Residual set at 100%.. Percent--- 4 7 13 ll. 5 Break of the specimen Tear strength Kg./cm. 44 47 50 44 44 27 Hardness ISO Kg./cm. 77 77 30 81 80 Characteristics of the crude mlx:

ML (1+4) C 108 78 53 38 26 Extrudabihty index at 10 0., Garvey 11 14 15 16 15 15 In Table 7 there are reported the mechanical character- EXAMPLE 9 1st1cs of the vulcanizates of nnxes containing the terpoly- 7 Mixes f making d d i l containing 50 Parts mer and polypropylene 1n varlous ratios. 6

of amorphous polypropylene as defined herein, 50 parts TABLE 7 Ratio ethylene-propylene-cyclooctadiene-1,5 terpolymer/polypropylene (parts by weight) Mechanical characteristics Units 100/0 90/10 70/30 50/50 30/70 Tensile strength Kg./cm. 183 162 98 61 Elongation at break. Percent 300 350 320 240 Elastic modulus at 30 KgJcm. 182 136 04 Elastic modulus at 200%- Kg./cm. 107 83 69 57 Elastic modulus at 100%- Kg./cm. 41 36 40 40 Residual set at 200%"..- Percent-.- 8. 5 13. 5 26 Tear strength Kg./cm. 45 50 49 42 ISO hardness 74 73 74, 5 78 81 Heat build up measured by Goodnch fleximeter, 201bs/30 O 40 51 Loss due to abrasion (Akron method). 00. 0. 207 0. 236 0. 214 ML (1+4) 100 C 91 64. 5 45 31 5 1 Break of the specimen. 2 In 1,000 revolutions X10 3 Not determined.

EXAMPLE 8 of ethylene/propylene/cyclooctadiene 1,5 terpolymer Mixes for making extruded articles were prepared by 75 with various Mooney viscosities, as well as a filler, anti- 1 1 oxidant and curing agents, were prepared on conventional roll mixers.

The compositions of the mixes were the following:

Parts by weight Ethylene/ (59% by mols) propylene/ (3% by mols) cyclooctadiene-1,5 terpolymer, ML (1+4) 100 Sulfur vulcanization in a press, 60 minutes at 150 C.

The influence of the Mooney viscosity of the ethylene/ propylene/cyclooctadiene terpolymer on the mechanical characteristics of the vulcanizates is shown in Table 9.

Mixes containing 50 parts of polypropylene as defined herein and 50 parts of terpolymers of difierent composition and, in addition, black fillers, anitoxidant and curing agents were prepared on conventional mixers of the art. Table 10 shows the compositions of the resulting mixes and the mechanical characteristics of the vulcanizates obtained from mixes diluted with the polypropylene, in comparison with the mechanical characteristics of the vulcanizates prepared with non-diluted mixes.

TABLE 10 Parts by weight Parts by weight Ethylene/(59% by mols) propylene/(3% by mols) cyclooctadiene-1,5 terpolymer, ML (1+4) 1 100 100 C.=84 Amorphous polypropylene HAF carbon black 50 Zinc oxide 5 Phenylbetanaphthylamine 1 Thiuramethylthiuchromedisulfide 1 Marcaptobenzothiazole 0.5

Sulfur 2 vulcanization in a press, 60 minutes at 150 C.

'lotal for both polymers, apportioned as set forth in Table 11.

The specimens Were placed in a circulating air oven at a temperature of about 150 C. and the determinations of the mechanical characteristics were carried out successively at regular time intervals.

The mechanical characteristics of the mixes as a function of time and of the ratio between the ethylene/propylene/cyclooctadiene-l,5 terpolymer and polypropylene are reported in Table 11.

TABLE 11 Ratio ethylene/propylene] cyelooctadiene-1,5 terpoly mer polypropylene Time in (a) (b) (c) (d) Mechanical characteristics days 100/0 90/10 /30 50/50 30 Tensile strength, kg./cm. 0 185 187 170 1 188 175 142 2 165 175 79 3 149 151 124 77 4 134 109 75 5 121 129 101 64 Elongation at break, perecnt 0 260 310 340 270 1 215 245 250 200 2 170 200 200 160 3 155 190 195 4 160 180 170 150 5 170 165 130 ISO Hardness 0 74 74. 5 77 4O 1 77. 5 76. 5 77 82 2 77 78 70 82 3 78. 5 76 79 82 4 76. 5 78. 5 82 5 78 77 83 Terpolymers (a) (b) (c) (d) (e) (i) Polypropylene 50 50 HAF carbon black. 50 50 50 50 Zinc oxide 6 5 5 5 5 Phenylbetanaphthylamine. 1 1 1 1 1 1 1 Tetramethylthiuramdisulfide. 1 1 1 1 1 1 1 Mercaptobenzothiazole 0. 5 0. 5 0. 5 0. 5 0. 5 0. 5 0. 5

Sulfur 2 2 2 2 2 2 2 2 vulcanization in a press, 60 minutes Tensile strength, kglem. 183 266 159 217 168 247 183 Elongation at break, percent... 300 375 420 410 300 330 305 375 Elastic modulus at 30% kg./cm. 184 122 115 212 153 243 139 Residual set at 200%, percent"- 6 13 8 17 6. 5 13. 5 5 12 Tear strength, kg./cm. 51 56 57 59 31 46 37 53 Hardness 1S0 78 78 76 75 78 75 74 73 EXAMPLE 11 EXAMPLE 12 According to ASTM D573/53 specifications, ageing tests were carried out on specimens type C (ASTM D412/64T) prepared from vulcanizates obtained from mixes based on ethylene/propylene/cyclooctadiene-1,5 terpolymer diluted with varying amounts of polypropylene as defined herein. The mixes had the following compositions:

Tests for evaluating the resistance to ozone were carried 70 out according to ASTM D1149/55T specifications on vulcanized specimens prepared according to D518/57T Method A specifications, and made up of 100 parts of the ethylene/propylene copolymer of Example 1 and of the terpolymers of Examples 7 and 10 extended with 50 7 parts by weight of the polypropylene, for 100 hours at a In Table 12, the mechanical characteristics of the vulcanizates of mixes containing the terpolymer and polypropylene in various ratios are reported.

TAB LE 12 Ratio of ethylene/propylene/B-methyl- 4,7,8,9-tetrahydroindene terpolymer polypropylene (parts by weight) (a) (d) Mechanical characteristics Units 100/0 90/10 70/30 50/50 30/70 Tensile strength Kg./cm. 256 252 225 136 85 Elongation at break Percent 295 300 355 325 240 Elastic modulus at 300%.. KgJcm 250 188 130 Elastic modulus at 200%. Kg./cm 160 129 100 83 69 Elastic modulus at l% Kg./em 54 47 44. 5 46 48 Percent. 7. 5 9 14 28 41 Kg./cm. 50 60 65 63 55 ISO Hardness 80 79 80. 5 84 88 Heat build up measured by Goodrich C 40 46 58 fieximeter, lbs/ C. Loss due to abrasion, Akron method" 0 175 0. 220 0.255 0. 255 ML (1+4) 100 C 120 99 71 49 1 Break of the specimen. 2 Ce. in 1,000 revolutions X10 3 Not determined.

cracking, similarly to the vulcanizates obtained from m1xes EXAMPLE 14 based on unextended olefin copolymer or terpolymer; also the mechanical characteristics were substantially unchanged.

EXAMPLE 13 Mixes for making molded articles were prepared by diluting an ethylene/propylene/6-methyl-4,7,8,9-tetrahydroindene terpolymer, on a conventional roll mixer, with varying amounts of polypropylene as defined herein and then adding black fillers, antioxidants and curing agents.

The compositions of the mixes were the following:

Parts by weight Ethylene/ (23% by mols) propylene/ (4% by mols) 6-methy1-4,7,8,9-tetrahydroindene terpoly- 1 100 mer, ML (1+4) 100 C.=107

Polypropylene HAF carbon black 50 Zinc oxide 5 Phenylbetanaphthylamine T 1 Tetramethylthiuramdisulphide 1 Mercaptobenzothiazole 0.5 Sulfur 2 vulcanization in a press, 60 minutes at 150 C.

Total for both polymers, apportioned as set forth in Table 12.

Mixes for making molded articles were prepared by diluting an ethylene/propylene/ethylidene-norbornene terpolymer, on a conventional roll mixer, with varying amounts of polypropylene as defined herein, and then adding black fillers, antioxidants and curing agents.

The compositions of the mixes were the following:

Parts by weight Ethylene/ (32.5% by mols) propylene/3.5% by mols) ethylidene-norbornene terpolymer, ML 1100 Vulcanization in a press, minutes at 150 C.

1 Total for both polymers, apportioned as set forth in Table 13.

In Table 13, the mechanical characteristics of the vulcanizates of mixes containing the terpolymer and polypropylene in various ratios are reported.

TABLE 13 Ratio ethyIene/propylene/ ethylidene-norbornene terpolymerzpolypropylene (parts by weight) (a) (b) (d) Mechamcal characteristics Units 100/0 90/10 /30 50/50 30/70 Tensile strength Kg./crn. 209 212 190 110 71 Elongation at break a Percent- 265 295 335 305 245 Elastic modulus at 300% Kg./cm. 143 105 Elastic modulus at 200% Kg./cm. 151 123 95 76 65 Elastic modulus at 1007 Kg./cm 60 51 45 46 48 Residual set at 200%- t. Percent 8 10 15 31 Tear strength. Kg./cm. 37 41 45 49 39 ISO Hardness 78 78 79 82 Heat build up measured by Goodrich C. 44 49. 5

fieximeter, 20 lbs/30 0. Loss due to abrasion, Akron methorL. Ce. 0. 195 0. 251 0. 275 ML (1+4) 100 C 79 56 39 29 1 Not determined. 2 Break of the specimen. 8 In 1,000 revolutions X 10 15 EXAMPLE 15 US. Pat. 3,240,727 to Scalari et al. discloses compositions of a major amount of amorphous polypropylene in admixture with a minor amount of a vulcanizable elastomeric copolymer for the preparation of expanded cellular materials. In Table 14 below, there are presented the compositions and results, in terms of elastomeric properties, of four experiments which were performed to demonstrate the criticality in the present invention of employing no more than 90 parts of amorphous polypropylene per 100 parts of vulcanizable copolymer or terpolymer. The markedly superior elastomeric characteristics of examples (b) and (d), containing the maximum amount of amorphous polypropylene which can be employed in accordance with the present invention, as compared to examples (a) and (c), respectively, wherein still more polypropylene is employed (a major amount as compared to the copolymer or terpolymer) demonstrates the criticality of this parameter in the present invention.

Another prior art patent, US. Pat. 3,210,301 to White, discloses the use of a minor amount of amorphous polypropylene as a processing aid in the recovery of reclaimed (already vulcanized) rubber. The experiments summarized in Table 15 demonstrate the remoteness of the disclosure of the White patent from the present invention. Thus, any attempt to apply the present invention to reclaimed rubber as opposed to unvulcanized elastomeric copolymers and terpolymers, even in example (c) of Table 15 wherein the reclaimed rubber was admixed with an equal amount of unvulcanized terpolymer, resulted in a product with very poor elastomeric properties. By comparison, much superior elastomeric properties were exhibited in experiment (d) of Table 15 wherein no amorphous polypropylene was employed. The vulcanization agents employed are those generally used for diene rubbers and mixtures of diene rubbers with reclaimed rubber.

TABLE 14 Amorphous polypropylene 100 90 100 00 Ethylene-propylene copolymer, 55%

by mols of ethylene-ML=80 80 100 HAF Carbon black 50 50 50 50 Zinc oxide 5 5 5 Polymerized 2,2,4-trimethyl-1,2-dihydroquinoiine. 0. 5 0. 5 Sulfur 0. 45 0. 45 2 2 Peroximon 2. 5 2. 5 Ethylene/propylene (59% by mols) eyelooetadlene -1,5 (3% by mols) terpolymer ML=84 80 100 Phenylbetanaphthylamine 1 1 Tetramethylthiuramdisulphide... 1 1 Mereaptobenzothiazole 0. 5 0. 5

40 minutes at 60 minutes at 165 0. 150 C.

vulcanization in a press:

Tensile strength, kgJem. 91 117 64 116 Elongation at break, percent 80 210 20 215 Elastic modulus at 300%, kg./em. Elastic modulus at 200%, kg./em.

Elastic modulus at 100%, kg./em. 85 Residual set at 100%, percent l R 25 l R 28 Shore A Hardness 83 84 87 85 l R indicates that specimen ruptured.

TABLE Amorphous polypropylene 90 35 Reelaimed rubber, prepared according to White 100 50 100 Ethylene/propylene (59% by mols)] eyelooetadiene-1,5 (3% by mols) terpolymer 50 HAF carbon black 50 50 50 50 Zinc de 5 5 5 5 Phenylbetanaphthylamine. 1 1 1 1 Stearie acid 0. 5 0. 5 0. 5 0.5 N-eyclohexyl-2-benzothiazylsulphenamide, Santoeure 1. 25 1. 25 1. 25 1. 25 Sulfur 1. 75 1. 75 1. 75 1. 75

60 minutes at 153 C. vulcanization:

Tensile strength, kgJemJ- 53 73 41 104-82 Elongation at break, percent- 65 25 60 50-35 Elastic modulus at 300%, kg./em. Elastic modulus at 200%, kgJcmJ. Elastiemodulus at 100%,kg./em 2 Residual set at 100%, percent"... 1 R Shore A Hardness 87 R indicates that specimen ruptured.

Variations can, of course, be made without departing from the spirit and scope of this invention.

Having thus described our invention what we desire to secure by Letters Patent and hereby claim is:

1. A vulcanizable composition comprising (1) a vul canizable polymeric elastomer selected from the group consisting of (a) high molecular weight, linear, amorphous, saturated coploymers of ethylene and a higher alpha-olefin selected from the group consisting of propylene and butene-l, and (b) high molecular weight, linear, amorphous, low-unsaturation terpolymers of ethylene, propylene, and a non-conjugated polyene selected from the group consisting of cyclooctadiene-1,5; dicyclopentadiene; cyclododecatriene 1,5,9; cyclododecadiene-1,7; cycloheptadiene-1,4; cyclohexadiene-1,4; norbornadiene; methyl-norbornene; dimethyl-tetrahydroindene; 6-methylheptadiene-1,5; hexadiene-l,4', 6-methyl 4,7,8,9 tetrahydroindene; and ethylidene-norbornene; (2) substantially amorphous polypropylene having a molecular weight in the range of about 14,000-48,000 as an extender for said vulcanizable polymeric material in an amount of from 1 to parts by weight per parts by weight of the vulcanizable polymeric elastomer; and (3) a curing agent selected from the group consisting of sulfur plus accelerators and an organic peroxide, said curing agent comprising both sulfur and an organic peroxide when said elastomer is copolymer (a).

2. The vulcanizable composition of claim 1 wherein the substantially amorphous polypropylene is present in an amount of from 10 to 70 parts by weight per 100 parts by weight of the vulcanizable polymeric elastomer.

3. The vulcanizable composition of claim 1 wherein the vulcanizable polymeric elastomer is a copolymer of ethylene and propylene.

4. The vulcanizable composition of claim 1 wherein the vulcanizable polymeric elastomer is a terpolymer of ethylene, propylene and cyclooctadiene-1,5.

5. The vulcanizable composition of claim 1 wherein the vulcanizable polymeric elastomer is a terpolymer of ethylene, propylene and dicyclopentadiene.

6. A process for preparing vulcanizates from the composition of claim 1 which comprises heating said composition to a vulcanization temperature between C. and 220 C.

7. The process of claim 6 wherein the vulcanization temperature is between C. and 180 C.

8. The composition of claim 1, cured to a vulcanized elastomer.

9. A vulcanizable composition comprising (1) a vulcanizable polymeric material selected from the group consisting of high molecular weight, linear, amorphous, low-unsaturation terpolymers of ethylene, propylene, and a non-conjugated polyene selected from the group consisting of cyclooctadiene-1,5; dicyclopentadiene; cyclododecatriene 1,5,9; cyclododecadiene-1,7; cycloheptadiene-1,4; cyclohexadiene-1,4; norbornadiene; methylnorbornene; dimethyl-tetrahydroindene; 6-methyl-heptadiene-1,5; hexadiene-1,4; 6-methy1 4,7,8,9 tetrahydroindene; and ethylidene-norbornene; (2) as an extender for said vulcanizable polymeric material, from 5 to 80 parts by weight per 100 parts by weight of the terpolymer of a substantially amorphous polypropylene having a molecular weight in the range of about 14,00048,000; and (3) a curing agent consisting of sulfur and an accelerator selected from the group consisting of tetramethylthiuramdisulfide, zinc diethyl dithiocarbamate, dipentamethylthiuramdisulfide, 2 mercaptobenzothiazole, dibenzothiazole disulfide and diphenylguanidine.

10. The vulcanizable composition of claim 1, which further includes a reinforcing filler.

11. The vulcanizable composition of claim 1, which further includes an antioxidant.

(References on following page) 17 18 References Cited FOREIGN PATENTS UNITED STATES PATENTS 1,345,254 10/1963 France 260-897 10/1966 Radclifi et a1. 260-41 MURRAY TILLMAN, Primary Examiner 6/1966 Corbelli 260-897 1 E I 3/1966 Scalari et al- 26025 5 C. I. S CCURO, Asslstant Examlner 10/1965 White 260-4 U.S.Cl.X.R.

4/1960 Gresham et a1. 260-805 260-41, 45.8, 45.9

mg UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3, 564, 080 Dated Februar 16, 1971 Inventor(s) GIOVANNI PEDRETTI, GINO PANCIROLI and AUGUSTO PORTC It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 2, Line 30: "pohsphoric" should read phosphoric Column 3, Line 54: "compolymers" should read copolymers Column 3, Line 64: After "influence", "or" should read or Column 6, Line ll: "'2, 2,3-trimethyl" should read 2,2,4-

trimethyl- Column 6, Line 60: "atmosphere" should read atmospheres Column 11, Table 10, first column line 1, following heading "Terpolymers": 5270 by mols) should read (52% by mols) Column 12, Line 10: 'Marcaptobenzothiazole" should read Mercaptobenzothiazole Column 14, Lines 39 and 40: "propylene/3.5% by mols) shoulz read propylene/(3.5% by mols} Column 15, Lines 2 and 3 of Table 14, first column: "Ethylex propylene copolymer, 55% by mols of ethylene ML=80" should read Ethylenepropylene copolymer, (55% by mols of ethylet ML=80) Column 15, Lines 2 and 3 of Table 15, first column: "Reclair rubber, prepared according to white" should read Reclaimec rubber (prepared according to White) Page mg? UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,564,080 Dated February 16, 1971 Invmumr(s)GIOVANNI PEDRETTI, GINO PANCIROLI and AUGUSTO PORT( It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

'Column 15, Line 12 of Table 15, first column: "amide,

Santoeure: should read amide (Santocure) Signed and sealed this 21st day of March 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents 

